Additive Bead Path Sequencing for Uniform-Temperature Shape Accuracy
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Solution Overview
Problem
The existing additive manufacturing methods, such as those described in Patent Literature 1, face challenges in achieving shape accuracy due to temperature differences between successive laminated bodies, leading to variations in shape and height of the manufactured objects.
Innovation Solution
An additive manufacturing method that involves forming linear beads in a predetermined sequence and under the same conditions, with specific gap formations between them, to maintain uniform temperature and improve shape accuracy, including forming first and second linear beads parallel to each other with gaps, and subsequent beads filling these gaps to maintain consistent conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the entire first laminated body is formed before forming the second laminated body, then the manufacturing process can be completed in sequence, but significant temperature differences occur between target surfaces leading to poor shape accuracy
Solution Approach 1:
The manufacturing process is segmented into multiple passes where not all linear beads of a layer are completed before moving to the next layer. Instead, the process alternates between layers by forming odd-numbered beads in the current layer and then even-numbered beads in the next layer, dividing the workload to maintain temperature uniformity across target surfaces.
Solution Approach 2:
The manufacturing process uses periodic action by alternating between forming beads in the first laminated body and beads in the second laminated body. This periodic switching ensures that no single target surface remains idle for too long, maintaining relatively uniform temperatures across all target surfaces and improving shape accuracy.
2Speed
If linear beads are formed continuously without gaps, then manufacturing time is reduced, but temperature variations increase leading to shape inaccuracies
Solution Approach 1:
The linear beads are segmented into odd-numbered and even-numbered groups with gaps between them. This segmentation allows the manufacturing process to switch between layers periodically, maintaining temperature uniformity while still progressing efficiently through the manufacturing sequence.
Solution Approach 2:
The process implements periodic action by forming odd-numbered linear beads with gaps, then switching to form even-numbered linear beads in the alternate layer. This periodic pattern maintains manufacturing speed while ensuring temperature uniformity across target surfaces, resolving the contradiction between speed and precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances the shape accuracy of manufactured objects by minimizing temperature-related variations and maintaining uniformity in bead formation, thereby improving the overall precision and flatness of the final product.
Implementation Method 1
an additive manufacturing device that performs additive machining for adding a wire 5 melted by beam irradiation onto a workpiece 17
Implementation Method 2
adding a wire 5 melted by beam irradiation
Implementation Method 3
a linear bead forming unit 10 that forms a linear bead 32 by causing a wire 5 to be melted and solidified in sequence
Data Source
AI summary
An additive manufacturing method includes: forming first and second linear beads parallel to each other under a same predetermined formation condition such that a gap having a predetermined width is formed between the first and second linear beads; forming a third linear bead in the gap under the same formation condition; forming, after forming the third linear bead, the linear bead that is formed as an even-numbered line under the formation condition such that the linear bead is parallel to the first linear bead and a gap having a predetermined width is formed between the linear bead formed as an even-numbered line and a linear bead formed two lines before; and forming, after forming the third linear bead, the linear bead that is formed as an odd-numbered line in the gap between the linear bead formed immediately before and the linear bead formed three lines before under the formation condition.